CN114423517B

CN114423517B - Reactor system for producing high value chemical products

Info

Publication number: CN114423517B
Application number: CN202180005403.3A
Authority: CN
Inventors: 陈雷; S·潘纳拉; D·韦斯特
Original assignee: SABIC Global Technologies BV
Current assignee: SABIC Global Technologies BV
Priority date: 2020-07-06
Filing date: 2021-07-06
Publication date: 2022-10-11
Anticipated expiration: 2041-07-06
Also published as: US20230123799A1; WO2022010821A1; EP3990166A4; CN114423517A; EP3990166A1; US11679370B2; US20230271157A1

Abstract

The present invention relates to a chemical reactor (100), the chemical reactor (100) having (a) two or more gas reactor elements (12), wherein each gas reactor element (12) has (i) a first reaction chamber (38), and (ii) a feed assembly unit (36); (b) A second reaction chamber (20) connected with each of the two or more gas reactor elements (12) and configured to independently receive two or more product streams from the two or more gas reactor elements (12); and optionally (c) a gas convergence section (40) located downstream of the second reaction chamber (20). The invention further relates to a method for producing a chemical product using the chemical reactor (100) of the invention.

Description

Reactor system for producing high value chemical products

Technical Field

The present invention relates to the field of chemical reactors, and in particular to the design of such chemical reactors suitable for the production of high value chemical products.

Background

Cost-effective production of commercial high-value chemicals such as alkenes and alkynes has been the subject of extensive research in the chemical industry for decades. Common methods in industry for producing such high value chemicals include steam cracking and pyrolysis of long chain hydrocarbons using conventional cracking furnaces (crackers) or pyrolysis reactors. Traditionally, steam crackers have been the reactor of choice in the industry to break down long chain hydrocarbons and convert smaller alkanes (i.e., naphtha, butane, ethane) to commercial high value chemicals. In such cracking furnaces, a hydrocarbon feedstock is typically fed into the furnace along with steam and converted to smaller olefins. Typically, the cracking process is carried out at high temperatures (i.e., 700 ℃ to 900 ℃) and has a residence time of about 100 to 500 milliseconds. Although hydrocarbon cracking and pyrolysis processes have been optimized over the past fifty years, there are still significant drawbacks and operational limitations that need to be overcome. Some of these drawbacks include: 1) heat losses and process complexity associated with separate exothermic (e.g., combustion in furnaces) and endothermic steps (e.g., cracking in process tubes), 2) the presence of inert compounds that adversely affect process efficiency, 3) metallurgical limitations of reactor components, when such components are subjected to extreme reactor severity, 4) coke deposition, which results in reactor plugging and increased capital and operating costs, 5) lack of feedstock flexibility, as commercial cracking furnaces/pyrolysis systems are typically optimized only for certain feedstock characteristics.

In another prior development, BASF developed a single stage combustion pyrolysis process for the production of acetylene, which is described in U.S. patent No. 5,789,644. The process has been commercialized in germany and the united states using multiple reactors on a 50kTA scale. In this process, natural gas is used as the hydrocarbon feedstock and pure oxygen is used as the oxidant to generate heat, which is critical for the production of acetylene. The two streams are premixed in a diffuser and the premixed fuel rich gas is combusted by partial oxidation using a furnace body. One major drawback of this design is the risk of flashback of the premixed flame under various feedstocks and operating conditions, and the use of multiple burners, which increase overall operating costs, thermal control difficulties, excessive coking, and low carbon yield towards olefin products. Furthermore, although acetylene has been the building block for chemicals in the past, olefins have been the building block for the chemical industry over the last six to seven decades, and it is desirable to produce olefins directly rather than using an indirect hydrogenation route for acetylene.

Some or all of the above-described drawbacks with respect to the operation of conventional cracking furnaces and pyrolysis reactors are addressed by the teachings provided in U.S. patent No. 11,020,719, which describes a pyrolysis reactor for converting hydrocarbons to acetylenes. Yet another solution to overcome some or all of the disadvantages of conventional cracking furnaces is described in international publication No. WO2020/086681 A2. While the productivity and conversion efficiency of the reactor systems described in U.S. Pat. No. 11,020,719 or international publication No. WO2020/086681A2 are promising, it would be desirable to further increase the production capacity while maintaining selectivity and hydrocarbon conversion by appropriate modification of the design of existing chemical reactor systems. It was observed in particular that as the size of the single reactor device described in U.S. Pat. No. 11,020,719 increases beyond a particular scale for the purpose of scaling up production, it was found that the selectivity and yield of the C2+ product was negatively affected because of the increased mixing time scale.

Accordingly, for the foregoing reasons, there remains a need to develop a chemical reactor for converting hydrocarbons to commercial high value chemicals at high production rates and increased process efficiencies while addressing one or more of the disadvantages typically associated with conventional cracking furnace or pyrolysis reactor systems.

Disclosure of Invention

The invention relates to a chemical reactor comprising: (a) Two or more gas reactor elements, wherein each of the gas reactor elements comprises: (i) A first reaction chamber having (1) an upstream end and (2) a downstream end, wherein the first reaction chamber is defined by a first reactor wall surrounding a first central longitudinal axis, wherein the first reaction chamber has an opening at the downstream end of the first reaction chamber; (ii) A feed assembly unit surrounding the first central longitudinal axis and operatively connected to the first reaction chamber, wherein the feed assembly unit comprises: 1) A mixing chamber defined by one or more feed assembly walls about a first central longitudinal axis, wherein the mixing chamber is operably connected to the upstream end of the first reaction chamber and at least one feed assembly wall is operably connected to the first reactor wall; and 2) two or more feed inlet flow spaces, each in fluid communication with the mixing chamber and configured to inject the feed stream into the mixing chamber in a radial and/or non-radial direction relative to the first central longitudinal axis; (b) A second reaction chamber connected (manifold to) to each of the two or more gas reactor elements and configured to independently receive two or more product streams from the two or more gas reactor elements, wherein the second reaction chamber has (i) a second central longitudinal axis, (ii) a downstream end, and (iii) an upstream end, and further wherein the second reaction chamber is defined by: (1) A second reactor wall surrounding a second central longitudinal axis and extending from an upstream end of the second reaction chamber to a downstream end of the second reaction chamber; and (2) a base plate extending across the second central longitudinal axis and located at an upstream end of the second reaction chamber, wherein the base plate is peripherally joined to the second reactor wall; further wherein the opening of each of the first reaction chambers forms a second reaction chamber inlet located at an upstream end of the second reaction chamber such that the first reaction chamber is in fluid communication with the second reaction chamber; and (3) one or more product outlets operably connected to a downstream end of the second reaction chamber; wherein for each of the two or more gas reactor elements, the first reaction chamber has a length of 1R to 10R, wherein 'R' is the radius of a circle, wherein the plane of the circle is oriented perpendicular to the first central axis and the circle has a maximum radius inscribable within an opening at the downstream end of the first reaction chamber, and further wherein the angle formed between the first central longitudinal axis and the second central longitudinal axis is from 0 ° to less than 180 °. In some preferred embodiments, for each of the two or more gas reactor elements, the opening at the downstream end of the first reaction chamber has an annular configuration with a radius 'R'. In some embodiments of the invention, the distance between any two adjacent gas reactor elements is from 0.5R to 5R, where 'R' is the radius of a circle, where the plane of the circle is oriented perpendicular to the first central axis, and the circle has the largest radius inscribable within an opening located at the downstream end of the first reaction chamber.

In some embodiments of the invention, the chemical reactor further comprises a gas converging (converting) section located downstream of the second reaction chamber, having (i) a downstream end in fluid communication with the one or more product outlets, and (ii) an upstream end in fluid communication with the downstream end of the second reaction chamber, and (iii) a central axis substantially coaxial with the second central longitudinal axis, wherein the gas converging section is defined by a wall surrounding the central axis, wherein the wall of the gas converging section is peripherally joined to the second reactor wall at the downstream end of the second reaction chamber.

In some preferred embodiments of the present invention, the angle formed between the first central longitudinal axis and the second central longitudinal axis is zero. In some embodiments of the invention, the angle formed between the first central longitudinal axis and the second central longitudinal axis is from 0 ° to 90 °. In some embodiments of the invention, 'R' has a value of 0.05 to 20 meters. In some embodiments of the invention, the chemical reactor comprises at least 3 gas reactor elements and at most 200 gas reactor elements.

In some embodiments of the invention, the feed assembly unit comprises: (a) A downstream feed assembly wall operably connected to the first reactor wall, wherein the downstream feed assembly wall surrounds a first central longitudinal axis; (b) An upstream feed assembly wall axially spaced upstream from the downstream feed assembly wall and surrounding the first central longitudinal axis; wherein the downstream feed assembly wall and the upstream feed assembly wall together define in part a mixing chamber for mixing the two or more feed streams, wherein the mixing chamber is operatively connected to the upstream end of the first reaction chamber; and (c) two or more feed inlet flow spaces, each in fluid communication with the mixing chamber and each configured to inject the feed stream into the mixing chamber in a radial and/or non-radial direction relative to the first central longitudinal axis.

In some embodiments of the invention, the base plate has two or more plate openings, each plate opening being connected to an opening of a first reaction chamber of the gas reactor element, such that two or more second reaction chamber inlets are positioned at the base plate. In some embodiments of the invention, the second reactor wall has two or more wall openings, each wall opening being connected to an opening of the first reaction chamber of the gas reactor element, such that the two or more second reaction chamber inlets are positioned at the second reactor wall. In some embodiments of the invention, the at least one second reaction chamber inlet is positioned at the second reactor wall and the at least one second reaction chamber inlet is positioned at the floor.

In some embodiments of the invention, the first reactor wall circumferentially surrounds the first central longitudinal axis, the second reactor wall circumferentially surrounds the second central longitudinal axis, and the floor is perpendicular to the second central longitudinal axis.

In some embodiments of the invention, each feed inlet flow space is provided with circumferentially spaced guide vanes oriented to promote radial flow of the feed stream relative to the first central longitudinal axis in a helical fluid flow pattern. In some embodiments of the invention, each feed inlet flow space is connected to a manifold configured to inject the feed stream tangentially into the feed inlet flow space.

In some embodiments of the invention, each gas reactor element further comprises a reactor inlet assembly located between the first reaction chamber and the feed assembly unit, wherein the reactor inlet assembly comprises a conduit defined by a peripheral wall (circumferential wall) surrounding the first central longitudinal axis and extending from an upstream end of the conduit to an opposite downstream end, wherein i) the downstream end of the conduit is in fluid communication with the upstream end of the first reaction chamber, and ii) the upstream end of the conduit is in fluid communication with the mixing chamber, and further wherein the downstream feed assembly wall engages the peripheral wall of the conduit at the upstream end of the conduit, and the first reactor wall circumferentially engages the peripheral wall of the conduit at the downstream end of the conduit. In some embodiments of the invention, the conduit of the reactor inlet assembly has a tapered width (tapering width) peripheral wall extending from the downstream and upstream ends of the conduit to an annular constricting neck located between the downstream and upstream ends of the conduit.

In some embodiments of the invention, the invention relates to a method of producing a chemical product using the chemical reactor of claim 1, wherein the method comprises: (a) Independently introducing two or more feed streams into at least two feed inlet flow spaces located in each of two or more gas reactor elements; (b) Mixing two or more feed streams in a mixing chamber of each gas reactor element and forming a swirling gas mixture; (c) Combusting a portion of the swirling gaseous mixture and forming a first product stream comprising a mixture of the combustion product stream and an unburned portion of the swirling gaseous mixture; (d) Introducing a portion of the first product stream into a first reaction chamber; (e) Subjecting a first product stream present in a first reaction chamber to first reaction conditions and forming a second product stream; (f) Introducing a portion of the second product stream into the second reaction chamber through the second reaction chamber inlet; (g) Subjecting two or more second product streams obtained independently from each gas reactor element to second reaction conditions and forming a third product stream; and (h) withdrawing a portion of the third product stream through one or more product outlets and obtaining a chemical product.

In some embodiments of the invention, the two or more feed streams comprise at least one hydrocarbon feed and at least one non-hydrocarbon feed. In some embodiments of the invention, the first reaction conditions and the second reaction conditions are reaction conditions suitable for cleavage. In some embodiments of the invention, the first reaction conditions and the second reaction conditions are reaction conditions suitable for pyrolysis. In some embodiments of the invention, the hydrocarbon feedstream is selected from methane, naphtha, LPG, liquid feeds, solid plastic particles, vaporized hydrocarbons having from 2 to 30 carbon atoms, and mixtures thereof. In some embodiments of the invention, the non-hydrocarbon feed stream is selected from the group consisting of oxygen, hydrogen, steam, carbon dioxide, carbon monoxide, and mixtures thereof.

Other objects, features and advantages of the present invention will become apparent from the following drawings, detailed description and examples. It should be understood, however, that the drawings, detailed description and examples, while indicating specific embodiments of the invention, are given by way of illustration only and are not meant as limitations. In addition, it is contemplated that modifications and variations within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any other embodiment. In further embodiments, additional features may be added to the specific embodiments described herein.

Drawings

For a more complete understanding, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a process flow diagram for converting a hydrocarbon feedstream to high value chemicals using a chemical reactor designed in accordance with an embodiment of the present invention and connected to a quench and an air separation unit.

Figure 2 is a cross-sectional view of a chemical reactor having three gas reactor elements connected to a second reaction chamber, wherein the angle formed between a first central longitudinal axis and a second central longitudinal axis is 0 °, designed according to one embodiment of the present invention.

Figure 3 is a cross-sectional view of a chemical reactor designed according to one embodiment of this invention having two gas reactor elements connected to a second reaction chamber, wherein the two second reaction chamber inlets are positioned at the floor and the angle formed between the first central longitudinal axis and the second central longitudinal axis is 30 °.

Fig. 4 is a cross-sectional view of a chemical reactor designed according to one embodiment of this invention having two gas reactor elements connected to a second reaction chamber, wherein two second reaction chamber inlets are positioned at the second reactor wall, wherein the angle formed between the first central longitudinal axis and the second central longitudinal axis is 90 °.

Fig. 5 is a cross-sectional view of a gas reactor element connected to a second reaction chamber and having two radial feed inlet flow spaces defined by a single gas separation wall.

Figure 6 is a cross-sectional view of a chemical reactor designed according to example 1 of this invention with seven gas reactor elements each connected to a second reaction chamber. For purposes of illustration, three representative gas reactor elements are shown in the figures.

Figure 7 is a cross-sectional view of a chemical reactor designed according to one embodiment of this invention having three gas reactor elements connected to a second reaction chamber, and each of the gas reactor elements having two coaxial feed inlet flow spaces.

Figure 8 illustrates a top (top) cross-sectional view of the swirling product stream from 7 different gas reactor elements, each of which is connected to a second reaction chamber, as one embodiment of the present invention. Fig. 8 shows, by way of particular example, the direction of rotation of the vortex flow, which may be the same for all gas reactor elements, or have different flow directions, to minimize flow interference between the gas reactor elements.

Figure 9 illustrates a top view (top) cross-sectional view of an opening at the downstream end of a first reaction chamber having a circle of radius 'R' inscribed in the opening as various embodiments of the present invention. Part (a) of fig. 9 shows a square configuration, part (b) of fig. 9 shows a ring-shaped (circular) configuration of the opening, and part (c) shows a triangular configuration of the opening.

Detailed Description

The present invention is based, in part, on a chemical reactor with a unique arrangement of reaction chambers that is suitable for converting hydrocarbon feeds to commercial high value chemical products at high production rates and increased process efficiencies. Advantageously, the present invention enables the skilled person to extend the production of commercial high value chemicals by co-assembling two or more of the reactor elements into a single reactor system.

The following includes definitions of various terms and phrases used in this specification.

The terms "weight%", "volume%", or "mole%" refer to the weight percent, volume percent, or mole percent of a component, respectively, based on the total weight, volume, or total moles of materials comprising the component. In one non-limiting example, 10 mole of a component in 100 moles of a material refers to 10 mole% of that component. The term "M" refers to the molar concentration of a component on a molar basis per 1L volume. The term "mM" means one thousandth of "M". Unless otherwise indicated, any numerical range used by this disclosure should include all values and ranges therebetween. For example, the boiling point range of 50 ℃ to 100 ℃ includes all temperatures and ranges between 50 ℃ and 100 ℃ and includes temperatures of 50 ℃ and 100 ℃.

The use of the terms "a" or "an" when used in conjunction with the terms "comprising," including, "" containing, "or" having "in the claims or the specification can mean" one, "but is also consistent with the meaning of" one or more, "" at least one, "and" one or more than one. The words "comprising" (and any form of comprising, such as "comprises" and "comprises"), "having" (and any form of having, such as "has" and "has"), "including" (and any form of including, such as "includes" and "includes") or "containing" (and containing any form, such as "containing" and "containing"), are inclusive or open-ended, and do not exclude additional, unrecited elements or method steps. The method of the invention may "comprise", "consist essentially of" or "consist of: specific ingredients, components, compositions, etc., are disclosed throughout this disclosure.

As used herein, the expressions "upstream" and "downstream" as used throughout this disclosure with respect to describing various components of the chemical reactor (100) of the present invention shall refer to the position of the reactor section or component with respect to the overall fluid flow direction. For example, the expression "upstream part of the reaction chamber" refers to a part of the reaction chamber where the gas stream is introduced or a part of the reaction chamber where the gas stream first flows into the reaction chamber. Thus, the expression "downstream part of the reaction chamber" refers to the part of the reaction chamber where the gas stream is present or flowing out.

The expression "operably connected" as used throughout this disclosure means that any two reactor component features or elements are directly or indirectly connected and that the flow of a gas or fluid stream occurs directly or indirectly from one element to another. For example, if element 'a' and element 'B' are operably connected, the gas or fluid stream may flow directly from 'a' to 'B', or the gas stream may flow indirectly through another element 'C' positioned between 'a' and 'B'.

The present invention relates to a chemical reactor having two or more gas reactor elements connected to a common reactor system configured to receive a product stream produced from each of the gas reactor elements. In some embodiments of the invention, each of the two or more gas reactor elements has the same features, components and configuration. Referring to fig. 2, in some embodiments of the invention, the invention relates to a chemical reactor (100) comprising: (a) two or more gas reactor elements (12); (b) A second reaction chamber (20), which may be considered a common reactor system, and which is connected to each of the two or more gas reactor elements (12) and is configured to independently receive a product stream from each of the two or more gas reactor elements (12); (c) A gas converging portion (40) located downstream of the second reaction chamber (20).

In some aspects of the invention, the chemical reactor (100) comprises at least 3 gas reactor elements and at most 200 gas reactor elements, or at least 4 gas reactor elements and at most 100 gas reactor elements, or at least 10 gas reactor elements and at most 20 gas reactor elements. In some preferred embodiments of the invention, the number of gas reactor elements (12) present in the chemical reactor (100) is seven. In some embodiments of the invention, each of the gas reactor elements (12) may have similar construction and similar components to those reactors described and shown in U.S. Pat. No. 11,020,719 and international publication No. WO2020/086681A2, each of which is incorporated herein by reference in its entirety for all purposes, including the description and discussion of the reactor construction and its various components.

Referring to fig. 5, in some embodiments of the invention, each of the gas reactor elements (12) comprises a first reaction chamber (38) having (1) an upstream end (33) and (2) a downstream end (34), wherein the first reaction chamber (38) is defined by a first reactor wall (39) about a first central longitudinal axis (35). In some embodiments of the invention, the first reactor wall (39) circumferentially surrounds the first central longitudinal axis (35) such that the first reactor wall (39) has a cylindrical configuration. In some embodiments of the invention, the first reactor wall (39) may have any of a cylindrical, square, oval, triangular, rectangular configuration, or any other shape or configuration without affecting the flow of the product stream from the first reaction chamber.

In some embodiments of the invention, the first reaction chamber has an opening at a downstream end of the first reaction chamber. The opening may have any suitable shape, such as circular, square, oval, triangular, rectangular, or any other shape or configuration, without affecting the flow of the product stream from the first reaction chamber. Referring to fig. 5, in some preferred embodiments of the invention, the first reaction chamber (38) has an opening (47) located at the downstream end (34) of the first reaction chamber (38). One convenient way to indicate the size of the opening (47) is to define the radius 'R' of the largest circle (having the largest radius) that can be inscribed within the opening (47). In other words, 'R' is the radius of a circle, wherein the plane of the circle is oriented perpendicular to the first central axis (35) and the circle has the largest radius inscribable within the opening at the downstream end of the first reaction chamber. The expression "inscribed" as used herein refers to a circle having the largest area that can fit within the opening (47). Fig. 9 provides an exemplary illustration of a largest circle of radius 'R', which may be inscribed within an opening (47) having various shapes and configurations. Thus, in some embodiments of the invention, the opening has a square configuration (part (a) of fig. 9) such that each side of the square has a length of 2R. Similarly, if the opening (47) is of circular or annular configuration (part (b) of fig. 9), the largest circle that may be inscribed in the opening (47) will have a radius equal to the radius of the opening (47). In some aspects of the invention, the 'R' has a value of 0.05 to 20 meters, alternatively 0.1 to 15 meters, alternatively 1 to 10 meters.

In some embodiments of the invention, the opening (47) at the downstream end (34) of the first reaction chamber (38) has an annular configuration with a radius 'R'. In some embodiments of the invention, the first reactor wall (39) has a cylindrical configuration, the opening (47) has an annular configuration, and the radial distance between the first central longitudinal axis (35) and the first reactor wall (39) is 'R'.

In some embodiments of the invention, the first reaction chamber (38) has a length of 1R to 10R, or 2R to 6R, or 4R to 8R, where 'R' is the radius of a circle, where the plane of the circle is oriented perpendicular to the first central axis (35), and the circle has a maximum radius that can be inscribed within an opening (47) located at the downstream end (34) of the first reaction chamber (38). In some aspects of the invention, the first reaction chamber (38) has a length of 0.05 meters to 200 meters, alternatively 0.2 meters to 90 meters, alternatively 4 meters to 80 meters.

Referring to fig. 2, the expression "length of the first reaction chamber" used throughout the present disclosure refers to the vertical length between the inlet (53) of the first reaction chamber (38) located at the upstream end of the first reaction chamber (38) and the opening (47) located at the downstream end of the first reaction chamber (38). To measure the length of the first reaction chamber (38), the transverse planar cross-section extending across the inlet (53) (perpendicular to the first central longitudinal axis) and the transverse planar cross-section extending across the opening (47) (perpendicular to the first central longitudinal axis) are considered to be the endpoints of the vertical length between the opening (47) and the inlet (53).

Referring to fig. 5, in some embodiments of the invention, each of the two or more gas reactor elements (12) has the same features, components and configuration, including the opening (47) of the first reaction chamber (38). In some preferred embodiments of the invention, the openings (47) have an annular configuration for each of the two or more gas reactor elements (12), and each has a radius of 'R'. In some aspects of the invention, the distance between any two adjacent gas reactor elements is 0.5R to 5R, or 0.8R to 3R, or 1R to 2R, where 'R' is the radius of a circle, where the plane of the circle is oriented perpendicular to the first central longitudinal axis (35), and the circle has a maximum radius inscribable within an opening (47) located at the downstream end (34) of the first reaction chamber (38). The distance between the gas reactor elements is measured by the radial distance between the first reactor walls of any two adjacent gas reactor elements.

As shown in figure 8, a top view (top) cross-sectional view of the swirling product stream from 7 different gas reactor elements, each of which is connected at the bottom to a second reaction chamber. Fig. 8 particularly shows the direction of rotation of the vortex flow, which may be the same for all gas reactor elements or have different flow directions to minimize flow interference between the gas reactor elements. In some aspects of the invention, the distance between any two adjacent gas reactor elements is from 0.025 meters to 100 meters, alternatively from 0.08 meters to 45 meters, alternatively from 1 meter to 20 meters. Without wishing to be bound by any particular theory, it is believed that by ensuring a suitable distance between adjacent gas reactor elements, the chance of poor flow dynamics of the product stream flowing into the second reaction chamber may be reduced, thereby enabling suitable operating efficiency of the chemical reactor (100) of the present invention.

Referring to fig. 5, in some embodiments of the invention, the feed assembly unit (36) of each gas reactor element (12) comprises: (a) A downstream feed assembly wall (29) operably connected to the first reactor wall (39), wherein the downstream feed assembly wall (29) surrounds a first central longitudinal axis (35); (b) An upstream feed assembly wall (28) axially spaced upstream from the downstream feed assembly wall (29) and surrounding a first central longitudinal axis (35); wherein the downstream feed assembly wall (29) and the upstream feed assembly wall (28) together define in part a mixing chamber (30) for mixing the two or more feed streams, wherein the mixing chamber (30) is operably connected to an upstream end (33) of the first reaction chamber (38); and (c) two or more feed inlet flow spaces, each in fluid communication with the mixing chamber (30) and configured to inject the feed stream into the mixing chamber (30) in a radial and/or non-radial direction relative to the first central longitudinal axis (35). In some embodiments, the feed injection may be tangential with respect to the first central longitudinal axis (35) such that the feed is introduced in an inward swirling flow pattern. In some aspects of the invention, the downstream feed assembly wall (29) and the upstream feed assembly wall (28) are oriented perpendicular to the first central longitudinal axis (35). The expression "configured to inject the feed stream into the mixing chamber in a radial direction" means that the feed is injected in a direction perpendicular or substantially perpendicular to the first central longitudinal axis (35) with a maximum deviation of 200. The expression "non-radial" as used herein refers to injection of feed in any direction other than the radial direction with respect to the first central axis.

In some preferred embodiments of the invention, the feed assembly unit (36) comprises two feed inlet flow spaces. Referring to fig. 5, in some preferred embodiments of the invention, the feed assembly unit (36) comprises two feed inlet flow spaces, the first (27) and second (26) feed inlet flow spaces each being configured to inject the feed stream into the mixing chamber (30) in a radial direction relative to the first central longitudinal axis (35), wherein each of the radial feed inlet flow spaces is defined by a gas partition wall (37) having a central opening (74) around the first central longitudinal axis (35). In some embodiments of the invention, the gas separation wall (37) is oriented perpendicular to the first central longitudinal axis (35). The first feed inlet flow space (27) is defined by an upstream feed assembly wall (28) and a gas dividing wall (37). The second feed inlet flow space (26) is defined by a downstream feed assembly wall (29) and a gas dividing wall (37).

Referring to fig. 7, in some embodiments of the invention, the feed assembly unit (36) includes one or more coaxial feed inlet flow spaces (93) and (94). In this case, two coaxial inlet flow spaces (93) and (94) are shown. Each configured to inject one or more feed streams into the mixing chamber in an axial direction relative to the first central longitudinal axis. In some embodiments of the invention, each of the axial feed inlet flow spaces (93) and (94) is connected to an opening at the upstream feed assembly wall such that the axial feed inlet flow spaces (93) and (94) are parallel to the first central longitudinal axis (35). The expression "axial feed inlet flow space" as used herein means that the feed is injected into the feed assembly unit (36) in a direction parallel or substantially parallel (up to 20 ° from the central axis) to the first central axis (35).

In some embodiments of the invention, each feed inlet flow space is provided with circumferentially spaced guide vanes, wherein each of such guide vanes is oriented to promote radial flow of the feed stream relative to the first central longitudinal axis in a helical fluid flow pattern. In some embodiments of the invention, each feed inlet flow space is connected to a manifold configured to inject the feed stream into the feed inlet flow space. In some aspects of the invention, the manifold is configured to inject the feed stream tangentially into the feed inlet flow space. In some aspects of the invention, each manifold comprises a gas inlet located at an outer periphery of the feed inlet flow space.

Referring to fig. 5, in some embodiments of the invention, the first feed inlet flow space (27) and the second feed inlet flow space (26) are provided with circumferentially spaced guide vanes (23) and (24), the guide vanes (23) and (24) being oriented to promote radial flow of the feed stream relative to the first central longitudinal axis (35) in a helical fluid flow pattern. In some embodiments of the invention, each of the feed inlet flow spaces (26) and (27) may be referred to as a radial feed inlet flow space. In some embodiments of the invention, the first feed inlet flow space (27), the second feed inlet flow space (26) are each connected to a manifold (50) and (51), respectively, and are configured to inject a feed stream into the respective feed inlet flow spaces. In some embodiments of the invention, manifolds (50) and (51) are each connected to a feed source comprising a hydrocarbon feed source or a non-hydrocarbon feed source.

In some aspects of the invention, the operation of manifolds (50) and (51) and the orientation of guide vanes (23) and (24) may be performed by a skilled artisan, as described in U.S. Pat. No. 11,020,719. For example, in some aspects of the invention, the feed stream from manifolds (50) and (51) is delivered tangentially to flow spaces (26) and (27), where guide vanes (23) and (24) further facilitate directing the feed stream to flow in an inward swirling or helical fluid flow pattern within flow spaces (26) and (27). In some aspects of the invention, the gas inlets (96), (97) from the manifolds (50) and (51), respectively, may be directed tangentially into the flow spaces (26), (27) such that the gas feed is not only directed radially from the inlets (96) and (97) towards the first central longitudinal axis (35), but also tangentially about the first central longitudinal axis (35) to provide a flow pattern of inward swirl. In some aspects of the invention, the gas inlets (96), (97) from the manifolds (50) and (51) are each connected to a feed source that supplies feed to the inlets.

In some aspects of the invention, each of the guide vanes (23) and (24) may be a planar member oriented in a plane parallel to the first central longitudinal axis (35) and extending between the walls (28), (29) and (37). In some aspects of the invention, the guide vanes (23) and (24) are circumferentially spaced an equal distance from each other. In some embodiments of the invention, the guide vanes (23) and (24) are fixed in a position in which the upper and lower side edges of the guide vanes (23) and (24) are joined to the walls (28), (29) and (37) along their length or a portion of their length such that there is no air gap between the side edges of the vanes (23) and (24) and the walls (28), (29) and (37).

In some embodiments of the invention, the guide vanes (23) and (24) are movable such that the upper and lower edges of the guide vanes (23) and (24) are closely spaced from the walls (28), (29) and (37) to provide a small gap for such movement while maintaining a minimum air gap for the feed gas to pass through. In some embodiments of the invention, the guide vanes (23) and (24) are oriented such that the planes of the guide vanes are in a non-parallel or oblique orientation with respect to the first central longitudinal axis (35). In this case, the side edges of the guide vanes (23) and (24) are fixed to the walls (28), (29) and (37) or are kept closely spaced from the walls (28), (29) and (37) to minimize air gaps for the feed to pass through. In some embodiments of the invention, each of the guide vanes (23) and (24) is configured as an airfoil having a curved surface and is oriented with a width parallel or non-parallel to the first central longitudinal axis (35) to provide a desired flow characteristic. The guide vanes (23) and (24) of each flow space (26) and (27) may be mounted on an actuator (not shown) such that they may be selectively moved to various positions to provide a selected inwardly spiraling flow pattern. The guide vanes (23) and (24) are pivotable about an axis parallel to the first central longitudinal axis (35) so that the vanes (23) and (24) can be moved to various positions.

In some aspects of the invention, the orientation of the guide vanes (23) and (24) and the orientation of the tangential gas inlets (96) and (97) are configured to ensure that the gas feed stream flows into the feed inlet spaces (26) and (27) in a swirling flow. In some embodiments of the invention, each of the guide vanes (23) and (24) may be oriented at a particular angle, referred to as angle a, formed between a line extending radially from the first central longitudinal axis (35) and a tangent representing the orientation of each of the guide vanes (23) and (24). This angle is shown in International publication No. WO2020/086681A 2. In some embodiments of the invention, angle a may be 50 ° to 85 °, or 60 ° to 75 °. In some aspects of the invention, the guide vanes (23) and (24) may be permanently oriented at an angle a within this range.

As shown in fig. 2, in some preferred embodiments of the invention, the feed module unit (36) comprises three gas separation walls, which are positioned axially between the upstream feed module wall and the downstream feed module wall, and each gas separation wall has a central opening, and each gas separation wall is oriented perpendicular to the first central longitudinal axis (35), as described in international publication No. WO2020/086681 A2. In some aspects of the invention, the three gas separation walls define, with the feed assembly walls, four feed inlet spaces configured to inject at least one hydrocarbon feed, at least one non-hydrocarbon feed, and at least one hydrogen-rich fuel stream, and steam into the feed assembly unit (36).

Referring to fig. 5, as an embodiment of the invention, each gas reactor element (12) further comprises a reactor inlet assembly (85) located between the first reaction chamber (38) and the feed assembly unit (36), wherein the reactor inlet assembly (85) comprises a conduit (86) defined by a peripheral wall (84), the peripheral wall (84) surrounding the first central longitudinal axis (35) and extending from an upstream end (87) of the conduit (86) to an opposite downstream end (88), wherein i) the downstream end (88) of the conduit (86) is in fluid communication with the upstream end (33) of the first reaction chamber (38), and ii) the upstream end (87) of the conduit (86) is in fluid communication with the mixing chamber (30), and further wherein the downstream feed assembly wall (29) engages the peripheral wall (84) of the conduit (86) at the upstream end (87) of the conduit (86), and the first reactor wall (39) circumferentially engages the peripheral wall (84) at the downstream end (88) of the conduit (86).

In some embodiments of the invention, the conduit (86) of the reactor inlet assembly (85) has a peripheral wall (84) of tapering width extending from the downstream end (88) and the upstream end (87) of the conduit (86) to an annular constricting neck (89) located between the downstream end (88) and the upstream end (87) of the conduit (86). In one aspect of the invention, the conduit (86) may be in the form of a venturi configured to increase the flow rate of the fluid mixture flowing from the feed assembly unit (36) to the first reaction chamber (38).

In some embodiments of the invention, the conduit of the reactor inlet assembly has a circumferential wall (not shown) of increasing width extending from the upstream end of the conduit to the downstream end of the conduit, such that the conduit has a diverging shape and configuration. The downstream portion of the duct (86) forms a diverging duct. The diverging conduit, as well as other diverging conduits described herein, is configured for non-supersonic fluid flow. A conduit or nozzle configured for supersonic flow, such as a de Laval nozzle, is configured differently from conduit (86) to provide supersonic flow downstream to form a shockwave. The diverging duct (86) does not form such supersonic flow or shockwave. Instead, the geometry of the conduit (86) facilitates recirculation and recirculation of gases within the internal reaction chamber (38) near the central longitudinal axis (35) and the annular vortical jet flow adjacent the internal reactor wall (39). As such, the diverging conduit (86) may have a divergence angle that is greater than the divergence angles typically used in de laval nozzles (e.g., 15 ° or less). In certain embodiments, the total divergence angle "B" (fig. 5) relative to axis (35) may be 25 ° or greater. In particular instances, the divergence angle B of the diverging conduits discussed herein is 25 ° to 55 °. In some embodiments, the divergence angle B is at least the following angle, equal to and/or between any two of the following angles: 25 °, 26 °, 27 °, 28 °, 29 °, 30 °, 31 °, 32 °, 33 °, 34 °, 35 °, 36 °, 37 °, 38 °, 39 °, 40 °, 41 °, 42 °, 43 °, 44 °, 45 °, 46 °, 47 °, 48 °, 49 °,50 °, 51 °, 52 °, 53 °, 54 °, and 55 °. The large divergence angle does not result in recirculation of the flow at the wall because in this unique design, the upstream swirling flow is coupled with a converging-diverging nozzle.

Referring back to fig. 5, in some aspects of the invention, the first reactor wall (39) is circumferentially surrounded along all or part of its length by an outer wall (41), wherein the outer wall (41) is positioned around the first reactor wall (39) and spaced apart from the first reactor wall (39) to form a cooling jacket, wherein a cooling fluid, such as water, is circulated through the jacket formed between walls (39) and (41). In some other embodiments of the invention, the outer wall (41) may be formed from one or more layers of refractory material, while the first reactor wall (39) may be formed from steel. Without wishing to be bound by any particular theory, it is believed that this arrangement helps to reduce heat loss and helps to maintain the high operating temperatures typically used within the first reaction chamber (38). Further, it is believed that in view of the unique design and operation of each of the gas reactor elements (12), the first reactor wall (39) is internally cooled by the high velocity near-wall gas flow that is urged toward the reactor wall (39) by centrifugal force, thereby making external cooling unnecessary in some embodiments of the present invention.

Referring back to fig. 2, the chemical reactor (100) includes a second reaction chamber (20), the second reaction chamber (20) being connected with each of the two or more gas reactor elements (12) and being configured to independently receive a product stream from each of the two or more gas reactor elements (12). The expression "independently receiving product streams" as used herein means that the product streams produced in each of the individual gas reactor elements (12) flow simultaneously into the second reaction chamber (20). In some embodiments of the invention, the second reaction chamber (20) has (i) a second central longitudinal axis (56), (ii) a downstream end (57), and (iii) an upstream end (58). In some aspects of the invention, the second reaction chamber (20) is configured to provide sufficient reaction conditions to further react a product stream flowing from the first reaction chamber (38) of each of the gas reactor elements (12) into the second reaction chamber (20).

In some aspects of the invention, the second reaction chamber (20) is defined by: (1) A second reactor wall (55) surrounding a second central longitudinal axis (56) and extending from an upstream end (58) of the second reaction chamber (20) to a downstream end (57) of the second reaction chamber (20); (2) A floor (60) extending across the second central longitudinal axis (56) and located at an upstream end (58) of the second reaction chamber (20), wherein the floor (60) is peripherally joined to the second reactor wall (55); and (3) a product outlet (68) operatively connected to the downstream end (57) of the second reaction chamber (20). The expression "circumferentially joined" as used herein means that all side edges of the bottom plate (60) are connected with the second reactor wall (55) such that the bottom plate (60) forms the bottom of the chemical reactor (100).

In some aspects of the invention, the opening (47) of each of the first reaction chambers (38) forms a second reaction chamber inlet (65) located at the upstream end (58) of the second reaction chamber (20) such that the first reaction chamber (38) is in fluid communication with the second reaction chamber (20).

In some embodiments of the invention, the second reactor wall (55) circumferentially surrounds the second central longitudinal axis (56) such that the second reactor wall (55) has a cylindrical configuration. In some embodiments of the invention, the floor (60) is perpendicular to the second central longitudinal axis (56). The length of the second reaction chamber (20) may be any suitable size depending on the desired residence time of the feed stream. In some embodiments of the invention, the second reaction chamber (20) has a length of 2R to 20R, 'R' being the radius of a circle, wherein the plane of the circle is oriented perpendicular to the first central longitudinal axis (35) and the circle has a maximum radius inscribable within an opening (47) located at the downstream end of the first reaction chamber (38) of each gas reactor element (12). In some embodiments of the invention, the second reactor wall (55) has a cylindrical configuration, wherein the second reaction chamber (20) has a radius of 2.25R to 52R. In some embodiments of the invention, the radius of the second reaction chamber (20) is from 0.15 meters to 1040 meters, alternatively from 0.15 meters to 50 meters, alternatively from 2 meters to 30 meters, alternatively from 5 meters to 20 meters.

In some aspects of the invention, the angle formed between the first central longitudinal axis (35) and the second central longitudinal axis (56) ranges from 0 ° to less than 180 °, or from 0 ° to 90 °, or from 10 ° to 45 °. In some preferred aspects of the invention, the angle formed between the first central longitudinal axis (35) and the second central longitudinal axis (56) is 0 °. As the skilled person will understand, when the angle between the first central longitudinal axis (35) and the second central longitudinal axis (56) is 0 °, the gas reactor element (12) is upright and the first central longitudinal axis (35) and the second central longitudinal axis (56) are parallel to each other.

Referring to fig. 2, in some embodiments of the invention, the base plate (60) has two or more plate openings (78), each plate opening being connected to an opening (47) of a first reaction chamber (38) of a respective gas reactor element (12), thereby positioning two or more second reaction chamber inlets (65) at the base plate (60). As can be appreciated by those skilled in the art, when the second reaction chamber inlet (65) is positioned at the bottom plate (60), the product stream from the first reaction chamber (38) of the gas reactor element (12) enters the second reaction chamber (20) from the bottom of the chemical reactor (100). As shown in fig. 2, as an embodiment of the present invention, the three gas reactor elements (12) are upright and form an angle of 0 ° between the first central longitudinal axis (35) and the second central longitudinal axis (56).

In some other embodiments of the invention, the gas reactor element (12) is oriented at a particular angle relative to the second reaction chamber (20), which may be an acute angle. As shown in fig. 3, two gas reactor elements (12) are connected to the second reaction chamber (20) and are circumferentially spaced from each other about the axis 56, wherein two second reaction chamber inlets (65) are positioned at the bottom plate (60), wherein the angle formed between the first central longitudinal axis (35) and the second central longitudinal axis (56) is 30 °.

In some aspects of the invention, the gas reactor element is positioned at the second reactor wall such that the inlet of the second reaction chamber is positioned on the reactor wall. Referring to fig. 4, in some aspects of the invention, a chemical reactor (100) has two or more gas reactor elements (12), each connected to a second reaction chamber (20), wherein two second reaction chamber inlets (65) are positioned at a second reactor wall (55), wherein an angle formed between a first central longitudinal axis (35) and a second central longitudinal axis (56) is 90 °. In some embodiments of the invention, two or more reactor elements (12) may be circumferentially spaced along the reactor wall (55) at different locations. In many embodiments, the gas reactor elements (12) may be equally spaced. Thus, in the embodiment of fig. 4, the two reactor elements (12) are shown as being spaced apart by about 180 °. If three reactor elements are used, they may be circumferentially spaced 120 ° apart, and so on. In other embodiments, the reactor elements may not be equally circumferentially spaced.

Referring back to fig. 2, in some aspects of the invention, the chemical reactor (100) includes a gas converging portion (40) located downstream of the second reaction chamber (20). In some embodiments of the invention, the gas converging portion (40) has (i) a downstream end (66) in fluid communication with a product outlet (68), and (ii) an upstream end (62) in fluid communication with a downstream end (57) of the second reaction chamber (20), and (iii) a central axis (64) substantially coaxial with the second central longitudinal axis (56). The expression "substantially coaxial" as used herein means that the second central longitudinal axis (56) is coaxial with the central axis (64), wherein the central axis (64) is oriented less than 10 ° with respect to the second central longitudinal axis (56). In some preferred aspects of the present invention, the central axis (64) and the second central longitudinal axis (56) are completely coaxial with each other such that the central axis (64) and the second central longitudinal axis (56) are the same and form an angle of 0 ° therebetween.

In some aspects of the invention, the gas converging portion (40) is defined by a wall (61) about a central axis (64), wherein the wall (61) of the gas converging portion (40) is circumferentially joined to the second reactor wall (55) at a downstream end (57) of the second reaction chamber (20). As used herein, the expression "circumferentially joined" means that the gas converging section (40) and the walls of the second reaction chamber (20) are connected at their edges such that at least 99 volume% of the product stream from the second reaction chamber (20) passes into the gas converging section (40). In some aspects of the invention, the wall (61) of the gas converging portion (40) circumferentially surrounds the second central longitudinal axis (56). In some embodiments of the invention, the wall has a tapered width extending from an upstream end (62) to converge at a downstream end (66) at a product outlet (68). The converging portion 40 may be a partial ellipsoid or sphere-like configuration. Without being bound by any particular theory, it is believed that the gas converging portion (40) allows for proper mixing and circulation of the product stream exiting the second reaction chamber (20) with a proper residence time for mixing before the product is withdrawn from the one or more product outlets. In some preferred embodiments, the gas converging section may be split into two sections, where each section is connected to a product outlet with a filter appropriately positioned to remove harmful particulates or reduce greenhouse gas emissions. In some aspects, the product outlet may be operated alternately, such that the filter at the product outlet may be changed without hindering operation.

In some aspects of the invention, the invention relates to a method of producing a chemical product using the chemical reactor of the invention, wherein the method comprises: (a) Independently introducing two or more feed streams into at least two feed inlet flow spaces located in each of two or more gas reactor elements; (b) Mixing the two or more feed streams in the mixing chamber of each gas reactor element and forming a swirling gas mixture; (c) Combusting a portion of the swirling gaseous mixture and forming a first product stream comprising a mixture of the combustion product stream and an unburned portion of the swirling gaseous mixture; (d) Introducing a portion of the first product stream into a first reaction chamber; (e) Subjecting a first product stream present in a first reaction chamber to first reaction conditions and forming a second product stream; (f) Introducing a portion of the second product stream into the second reaction chamber through the second reaction chamber inlet; (g) Subjecting two or more second product streams obtained independently from each gas reactor element to second reaction conditions and forming a third product stream; and (h) withdrawing a portion of the third product stream through one or more product outlets and obtaining a chemical product. In some embodiments of the invention, a portion of the third product stream is first introduced into the gas converging section and subsequently withdrawn through one or more product outlets.

In some embodiments of the invention, the two or more feed streams comprise at least one hydrocarbon feed and at least one non-hydrocarbon. In some embodiments of the invention, the hydrocarbon feedstream is selected from methane, naphtha, LPG, liquid feeds, solid plastic particles, vaporized hydrocarbons having from 2 to 30 carbon atoms, and mixtures thereof. In some embodiments of the invention, the non-hydrocarbon feedstream is selected from the group consisting of oxygen, hydrogen, steam, carbon dioxide, carbon monoxide, and mixtures thereof. In certain embodiments of the invention, the molar ratio of hydrocarbon feed to non-hydrocarbon feed is from 1 to 5, more particularly from 1 to 4, more particularly from 1.5 to 2.5, even more particularly from 1.8 to 2. Such ratios may depend on the particular operating conditions and desired product to be formed.

Referring to fig. 5, as an embodiment of the present invention, two feed streams are introduced separately into the first (27) and second (26) feed inlet flow spaces of the reactor element (12), respectively. In some embodiments of the invention, the feed introduced into the feed inlet flow space (27) is oxygen. In some embodiments of the invention, the feed introduced into the feed inlet flow space (26) is methane or a hydrocarbon feed having from two to ten carbon atoms. Optionally, additional feed streams comprising steam and/or hydrogen-rich fuel may be introduced into the mixing chamber (30) using additional feed inlet flow spaces.

The separate introduction of the feed streams into the feed flow space rather than in the form of a mixture reduces the risk of any unsafe operating problems. In some embodiments of the invention, the feed stream is introduced tangentially into the feed inlet flow spaces (27) and (26). The injected feed streams are mixed in a mixing chamber (30) to form a swirling gas mixture. In some embodiments of the invention, a portion of the swirling gas mixture may be combusted to provide the necessary heat supply for the hydrocarbon conversion process in the first reaction chamber (38). Combustion of a portion of the swirling gaseous mixture results in the formation of a first product stream. In some embodiments of the invention, at least a portion (at least 95 vol%) of the first product stream enters the first reaction chamber (38) through a conduit (86) of a reactor inlet assembly (85).

The first product stream is a mixture of products obtained from the partial combustion of the swirling gas mixture and the unburned portion of the swirling body mixture. In some embodiments of the invention, a portion of the first product stream is subjected to first reaction conditions to form a second product stream. In some embodiments of the invention, the first reaction conditions are suitable for pyrolyzing a portion of the first product stream present in the first reaction chamber (38). In some embodiments of the invention, the first reaction conditions are suitable for cracking the first product stream present in the first reaction chamber (38).

In some embodiments of the invention, the first reaction conditions are suitable for cracking or pyrolyzing a mixture of a hydrocarbon feed stream and a non-hydrocarbon feed stream at a temperature of from 1000 ℃ to 3000 ℃, at a pressure of from greater than 0 bar absolute to 10 bar absolute, and at a gas flow rate of from greater than 0 to 120 t/h. As used herein, a gas flow rate value is a flow rate suitable for operating a single gas reactor element. The heat provided by the partial combustion of the swirling gaseous mixture in the mixing chamber (30) helps to impart first reaction conditions suitable for pyrolysis or cracking of at least a portion of the first product stream.

In some embodiments of the invention, the second reaction conditions are suitable for cracking or pyrolyzing a mixture of the hydrocarbon feed stream and the non-hydrocarbon feed stream under temperature conditions (800 ℃ to 2000 ℃), pressure conditions (greater than 0 bar absolute to 10 bar absolute), and flow rate conditions (greater than 0 to 120 'N't/h), where 'N' is the total number of gas reactor elements connected to the second reaction chamber (20). The gas flow rate in the second reaction chamber is increased by a multiplication factor (multiplier factor) of the number of gas reactor elements connected to the second reaction chamber (20).

In some embodiments of the invention, at least 95 vol%, or at least 99 vol% of the first product stream is introduced into the first reaction chamber. In some embodiments of the invention, 100% by volume of the first product stream is introduced into the first reaction chamber. In some embodiments of the invention, at least 90 vol%, alternatively at least 95 vol%, alternatively at least 99 vol% of the second product stream is introduced into the second reaction chamber. In some embodiments of the invention, 100% by volume of the second product stream is introduced into the second reaction chamber. In some embodiments of the invention, at least 90 volume%, alternatively at least 95 volume%, alternatively at least 99 volume% of the third product stream is introduced into the gas converging section. In some embodiments of the invention, 100% by volume of the second product stream is introduced into the gas converging section.

In some embodiments of the invention, the second product stream comprises hydrocarbon pyrolysis products. In some other embodiments of the invention, the second product stream comprises a cracked hydrocarbon product. The gas feed streams may be introduced to provide different flow rates to provide Kelvin-Helmholtz instability to enhance mixing. In some aspects of the invention, the chemical reactor operates with a gas residence time of greater than 0 to 10 milliseconds within the first reaction chamber and a gas residence time of greater than 0 to 25 milliseconds within the second reaction chamber. In particular, the residence time may be adjusted depending on whether the chemical reactor is used for pyrolysis or cracking of the feed stream. For example, for pyrolysis, the total residence time in the reactor system prior to quenching is less than 10 milliseconds in some cases, and when cracking is performed using the feed, the total residence time in the reactor system prior to quenching is less than 15 milliseconds in some cases.

Referring to fig. 2, as an embodiment of the invention, in some aspects of the invention, the second reaction chamber (20) is configured to independently receive a second product stream from each of the gas reactor elements (12) connected to the second reaction chamber (20). In some embodiments of the invention, a portion of the second product stream is passed into the second reaction chamber (20) through the second reaction chamber inlet (65), where a portion of the second product stream is subjected to second reaction conditions to form a third product stream.

The third product stream comprises the product stream received from each of the individual gas reactor elements (12) and additional hydrocarbon pyrolysis or cracked hydrocarbon products produced in the second reaction chamber (20). In some embodiments of the invention, the second reaction conditions are the same as the first reaction conditions and are suitable for pyrolyzing or cracking a portion of the second product stream present in the second reaction chamber (20). In some aspects of the invention, a portion of the third product stream enters the gas converging section (40) and then a portion (at least 95 vol%) or all of the third product stream is withdrawn through the product outlet (68) to obtain the chemical product.

In some embodiments of the invention, the chemical product produced in the chemical reactor (100) of the invention, after being withdrawn from the product outlet (68), may be quenched and subjected to further processing and recycling, as shown in fig. 1. More specifically, as shown in fig. 1, the chemical product (15) is withdrawn from the chemical reactor (100), where the chemical product (15) may be cooled by quenching in a quenching unit (14), such as a water droplet spray quench vessel or other suitable gas quenching device. The chemical product (15) typically comprises a mixture of cracked hydrocarbon products, hydrogen, steam, oxygenates, C4+ hydrocarbons, aromatics, and product olefins. The feed injected into the chemical reactor (100) originates from an air separation unit (10) and a hydrocarbon feed source (9), wherein the feed is introduced in the form of two separate streams (16) and (17).

In some aspects of the invention, the quenched chemical product (18) may be sent to a separation unit (21) where the product gas is separated to form a product stream (19) containing commercial high value products such as olefins, including ethylene, propylene, etc., and a separated gas stream (11). In some embodiments of the invention, the separated gas stream (11) typically comprises hydrogen (H) ₂ ) A small amount of methane (CH) ₄ ) And CO ₂ Carbon oxides, which may be recycled back to the chemical reactor (100). The product stream (19) may be subjected to further treatment in a treatment unit (22). Thus, the present invention enables one to design a chemical reactor for use with a conventional cracking furnace or pyrolysisThe chemical reactor is suitable for scale-up production of commercially high value chemicals with excellent feed conversion and selectivity, particularly high overall C2+ yield, as compared to the reactor. The inventive chemical reactor of the present invention is relatively simple in construction, which significantly reduces capital and operating costs, and allows for the large-scale production of high-value chemical products. In particular, the present invention provides the following advantages: (1) The novel swirling flow dynamics provides high temperature combustion gases at the core of the reactor and minimizes heat loss; (2) shorter residence times reduce coke formation; (3) The compact non-premixed flame provides a stable heat source for pyrolysis and reduces the risk of flashback; (4) The reactor is flexible, and can convert various raw materials or mixed raw materials into high-value olefin and other chemicals; (5) The high centrifugal force of the swirling gas mixture ensures a stratified flow between the cracking feedstock and the oxidant radicals promoting higher yield and selectivity; (6) The reactor system allows for the use of hydrogen rich fuels, thereby minimizing byproduct formation by scavenging oxygen radicals to form water; (7) Process intensification is performed by combining exothermic and endothermic steps in a single reactor system; (8) Simple operation, resulting in reduced capital costs and lower operating expenses; (9) Rapid mixing between the combustion products and the pyrolysis/cracking products provides control over the temperature of the mixed recirculation zone (control of the temperature of the hydrocarbon conversion zone); (10) The reactor can be operated at high flow rates with controlled residence time; (11) The flexible fuel burner enables the technician to burn a hydrocarbon or mixture without the usual problems of flame stability or flame impingement.

The following includes specific examples that illustrate some embodiments of the invention. These examples are for illustrative purposes only and are not intended to limit the present invention. It should be understood that the embodiments and aspects disclosed herein are not mutually exclusive and that these aspects and embodiments may be combined in any manner. One of ordinary skill in the art can readily recognize parameters that may be changed or modified to produce substantially the same results.

Detailed Description

Examples

Example 1

Pyrolysis of methane for acetylene production

The purpose is as follows: example 1 illustrates a process for the pyrolysis of methane to acetylene using an inventive chemical reactor designed as an embodiment of this invention. In particular, the reactor of the present invention uses seven gas reactor elements to produce 15kTA of C2+ hydrocarbons, particularly acetylene, with CO and H2 as by-products.

The method comprises the following steps: using for ANSYS

Commercial software available from software products Computational Fluid Dynamics (CFD) simulations were performed for the optimal design of the cleavage reactor as already described herein to verify its performance by numerical experiments. Vortex fluid flow, heat transfer and detailed gas phase reactions are modeled in a two-dimensional axisymmetric CFD framework using a reynolds stress turbulence model using the reynolds mean navier-stokes (RANS) method.

Operating parameters: the hydrocarbon feed stream used for the purposes of example 1 was methane and the nonhydrocarbon feed stream used was pure oxygen. The following reactor configurations and operating parameters were used for the models shown in tables 1, 2 and 3 below:

table 1: reactor structure

Table 2: reactor feed operating conditions

Table 3: process conditions

For the purposes of example 1, and as shown in fig. 6, a simulation study was conducted on a chemical reactor (100) involving seven different gas reactor elements (12). However, for illustrative purposes, a representative three gas reactor element (12) is shown in fig. 6. The gas reactor element (12) is configured as shown in fig. 5 and is vertically oriented such that the first central longitudinal axis (35) and the second central longitudinal axis (56) are parallel to each other. The feed assembly unit (36) has a gas separation wall (37), and an upstream feed assembly wall (28) and a downstream feed assembly wall (29). A non-hydrocarbon feed stream of oxygen is introduced into the first feed inlet flow space (27) by manifold (50) and a hydrocarbon feed stream of methane is introduced into the second feed inlet flow space (26) by manifold (51). The methane and oxygen feed streams are introduced separately and mixed in a mixing chamber (30) to form a swirling gas mixture.

Referring to fig. 5, a portion of the swirling gaseous mixture is combusted to form a first product stream comprising a mixture of the combustion product stream and an unburned portion of the swirling gaseous mixture. The first product stream is introduced into the first reaction chamber (38) through a conduit (86) of a reactor inlet assembly (85). Almost all (> 99%) of the first product stream is subjected to the first reaction conditions to form a second product stream. Almost all of the thus obtained second product stream (> 99 vol%) is introduced into the second reaction chamber (20) through the second reaction chamber inlet (65). A second product stream obtained from each of the seven gas reactor elements (12) is simultaneously introduced into a second reaction chamber (20). The mixture formed from the mixing of the second product streams obtained from the seven gas reactor elements is subjected to the second reaction conditions of pyrolysis to form a third product stream. Almost all of the third product stream (> 99 vol%) is introduced into the gas converging section (40) and then almost all of the third product stream (> 99 vol%) is passed through the product outlet (68) to obtain a chemical product containing acetylene and other pyrolysis by-products. A general schematic of this process is implemented as shown in fig. 1.

Comparative example: as a comparative example, a feed mixture of methane and oxygen in the proportions shown in example 1 was introduced into the same single gas reactor element as disclosed in U.S. patent No. 11,020,719. The feed mixture introduced into the chemical reactor was subjected to pyrolysis conditions as described for the gas reactor element in example 1 of the present invention. However, for the comparative reactor system, the chemical product obtained from a single gas reactor element was not introduced into the second reaction chamber, but was directly withdrawn from the gas reactor element and analyzed for product yield, selectivity measurements.

As a result: the chemical products obtained from the chemical reactor system of the present invention and the comparative system were analyzed in detail. The simulation software was configured to calculate the yield, conversion and selectivity parameters as shown in table 4 below.

Table 4: product analysis

	Inventive example 1	Comparative example 1A
			C ₂₊ Hydrocarbon yield (%)	25％	27％
Methane conversion (%)	82％	82％
			C ₂₊ Selectivity is	30.5％	33％

From the results shown in table 4, the inventive chemical reactor with its unique configuration is able to provide similar methane conversion, C2+ hydrocarbon yield and selectivity, which enables scaling up the reactor with similar performance, compared to the existing single element reactor system described in U.S. patent No. 11,020,719 (comparative example 1A).

While the invention has been shown in some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes and modifications without departing from the scope of the invention based on experimental data, or other optimizations which take into account the overall economics of the process. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.

Claims

1. A chemical reactor, comprising:

a. two or more gas reactor elements, wherein each of the gas reactor elements comprises:

i. a first reaction chamber having (1) an upstream end and (2) a downstream end, wherein the first reaction chamber is defined by a first reactor wall surrounding a first central longitudinal axis, wherein the first reaction chamber has an opening at the downstream end of the first reaction chamber;

a feed assembly unit surrounding the first central longitudinal axis and operatively connected to the first reaction chamber, wherein the feed assembly unit comprises: 1) A mixing chamber defined by one or more feed assembly walls about the first central longitudinal axis, wherein the mixing chamber is operably connected to the upstream end of the first reaction chamber and at least one feed assembly wall is operably connected with the first reactor wall; and 2) two or more feed inlet flow spaces, each in fluid communication with the mixing chamber and configured to inject a feed stream into the mixing chamber in a radial and/or non-radial direction relative to the first central longitudinal axis;

b. a second reaction chamber connected with each of the two or more gas reactor elements and configured to independently receive two or more product streams from the two or more gas reactor elements, wherein the second reaction chamber has (i) a second central longitudinal axis, (ii) a downstream end, and (iii) an upstream end, and further wherein the second reaction chamber is defined by:

(1) A second reactor wall surrounding the second central longitudinal axis and extending from the upstream end of the second reaction chamber to the downstream end of the second reaction chamber;

(2) A bottom plate extending across the second central longitudinal axis and located at the upstream end of the second reaction chamber, wherein the bottom plate is peripherally joined with the second reactor wall; further wherein the opening of each of the first reaction chambers forms a second reaction chamber inlet located at an upstream end of the second reaction chamber such that the first reaction chamber is in fluid communication with the second reaction chamber; and

(3) One or more product outlets operably connected to the downstream end of the second reaction chamber; and is

Wherein, for each of the two or more gas reactor elements, the first reaction chamber has a length of 1R to 10R, wherein 'R' is the radius of a circle, wherein the plane of the circle is oriented perpendicular to the first central axis and the circle has a maximum radius that can be inscribed within the opening at the downstream end of the first reaction chamber, and further wherein the angle formed between the first central longitudinal axis and the second central longitudinal axis is comprised between 0 ° and less than 180 °.

2. The chemical reactor of claim 1 wherein, for each of the two or more gas reactor elements, the opening at the downstream end of the first reaction chamber has an annular configuration with a radius 'R'.

3. The chemical reactor of claim 1, wherein the chemical reactor further comprises a gas converging portion located downstream of the second reaction chamber, the gas converging portion having (i) a downstream end in fluid communication with one or more product outlets, and (ii) an upstream end in fluid communication with the downstream end of the second reaction chamber, and (iii) a central axis substantially coaxial with the second central longitudinal axis, wherein the gas converging portion is defined by a wall surrounding the central axis, wherein the wall of the gas converging portion is peripherally joined to the second reactor wall at the downstream end of the second reaction chamber.

4. The chemical reactor of claim 1 wherein the feed assembly unit comprises:

a. a downstream feed assembly wall operatively connected to the first reactor wall, wherein the downstream feed assembly wall surrounds the first central longitudinal axis;

b. an upstream feed assembly wall axially spaced upstream from the downstream feed assembly wall and surrounding the first central longitudinal axis; wherein the downstream feed assembly wall and the upstream feed assembly wall together partially define the mixing chamber for mixing two or more feed streams, wherein the mixing chamber is operably connected to the upstream end of the first reaction chamber; and

c. two or more feed inlet flow spaces each in fluid communication with the mixing chamber and each configured to inject a feed stream into the mixing chamber in a radial and/or non-radial direction relative to the first central longitudinal axis.

5. The chemical reactor of claim 1 wherein the distance between any two adjacent gas reactor elements is 0.5R to 5R, where 'R' is the radius of a circle, wherein the plane of the circle is oriented perpendicular to the first central axis, and the circle has a maximum radius capable of inscribed within the opening at the downstream end of the first reaction chamber.

6. The chemical reactor of claim 1, wherein an angle formed between the first central longitudinal axis and the second central longitudinal axis is 0 ° to 90 °.

7. A chemical reactor as claimed in claim 1, wherein the base plate has two or more plate openings, each plate opening being connected to the opening of a first reaction chamber of a gas reactor element, such that the two or more second reaction chamber inlets are positioned at the base plate.

8. The chemical reactor according to claim 1, wherein the second reactor wall has two or more wall openings, each wall opening being connected to the opening of the first reaction chamber of a gas reactor element, such that the two or more second reaction chamber inlets are positioned at the second reactor wall.

9. The chemical reactor of claim 1 wherein the chemical reactor comprises at least 3 gas reactor elements and at most 200 gas reactor elements.

10. The chemical reactor of claim 1 wherein 'R' has a value of 0.05 to 20 meters.

11. The chemical reactor of claim 1 wherein each feed inlet flow space is provided with circumferentially spaced guide vanes oriented to encourage feed flow radially relative to the first central longitudinal axis in a spiral fluid flow pattern.

12. The chemical reactor of claim 4, wherein each gas reactor element further comprises a reactor inlet assembly located between the first reaction chamber and the feed assembly unit, wherein the reactor inlet assembly comprises a conduit defined by a peripheral wall surrounding the first central longitudinal axis and extending from an upstream end of the conduit to an opposite downstream end, wherein i) the downstream end of the conduit is in fluid communication with the upstream end of the first reaction chamber and ii) the upstream end of the conduit is in fluid communication with the mixing chamber, and further wherein the downstream feed assembly wall engages the peripheral wall of the conduit at the upstream end of the conduit and the first reactor wall circumferentially engages the peripheral wall of the conduit at the downstream end of the conduit.

13. The chemical reactor of claim 12 wherein the conduit of the reactor inlet assembly has a peripheral wall that tapers in width extending from the downstream and upstream ends of the conduit to an annular constricted neck located between the downstream and upstream ends of the conduit.

14. The chemical reactor of claim 1, wherein each feed inlet flow space is connected to a manifold configured to inject a feed stream tangentially into the feed inlet flow space.

15. A method of producing a chemical product using the chemical reactor of claim 1, wherein the method comprises:

a. independently introducing two or more feed streams into at least two feed inlet flow spaces located in each of the two or more gas reactor elements;

b. mixing the two or more feed streams in the mixing chamber of each gas reactor element and forming a swirling gas mixture;

c. combusting a portion of the swirling gaseous mixture and forming a first product stream comprising a mixture of a combustion product stream and an unburned portion of the swirling gaseous mixture;

d. introducing a portion of the first product stream into the first reaction chamber;

e. subjecting the first product stream present in the first reaction chamber to first reaction conditions and forming a second product stream;

f. introducing a portion of the second product stream into the second reaction chamber through a second reaction chamber inlet;

g. subjecting two or more second product streams independently obtained from each gas reactor element to second reaction conditions and forming a third product stream; and

h. a portion of the third product stream is withdrawn through one or more product outlets and a chemical product is obtained.

16. The method of claim 15, wherein the two or more feed streams comprise at least one hydrocarbon feed stream and at least one non-hydrocarbon feed.

17. The method of claim 15, wherein the first reaction conditions and the second reaction conditions are reaction conditions suitable for cleavage.

18. The method of claim 15, wherein the first reaction conditions and the second reaction conditions are reaction conditions suitable for pyrolysis.

19. The process of claim 16, wherein the hydrocarbon feedstream is selected from methane, ethane, propane, butane, naphtha, LPG, liquid feeds, solid plastic particulates, vaporized hydrocarbons having from 2 to 30 carbon atoms, and mixtures thereof.

20. The process of claim 16, wherein the non-hydrocarbon feedstream is selected from oxygen, hydrogen, steam, carbon dioxide, carbon monoxide, and mixtures thereof.